This tool is designed to allow step-by-step forming of of the tubing shown
in the picture of the building light above. We also have a kit (NK015) which
includes enough parts to build 8 of these lights. More information about the
kit can be found here.

The first step in
building this gooseneck light is to flare the end of a segment of the .018”
tubing.
The complete procedure for doing this can be found
here (under cold flaring).

Once the tubing has been flared, the next step is forming the gooseneck
shape and that is where this tool is used. Following is the step-by-step
procedure:

Bending
the tubing

The tool (pictured
below) consists of an aluminum block which contains 5 holes, and 5 .125"
diameter pins which fit into the holes. The holes are located in a pattern that with
pins inserted, provide a bending pattern that the .018" tubing can be formed
around to achieve the gooseneck shape.

The diagram below
shows the tubing in position in the tool.

Note that the flared end of the tubing is aligned with the bottom edge of
the first pin. A line could be scratched in the fixture surface to assist in
alignment as well. Note that we’ve labeled 3 of the pins around which the tubing is to be bent,
1, 2, and 3. The bending
procedure is as follows:

Clamp the bending fixture in a bench mounted vise or some holding
fixture to ensure it will remain stationary during the tubing
bending process.

Place a segment of flared tube with the .012" stainless steel wire
inserted approx. 1” into the flared end of the tube, into the
fixture so the flare is positioned as shown in the picture (aligned
with the bottom edge of the first pin).

Holding the tubing down against the fixture surface, gently wrap the
tube around the second pin 180 degrees in the clockwise direction to
form a half-circle as shown. Bend slightly past 180 degrees so the tube
will just clear the insertion of pin, marked 1 in the
drawing when the tube is in a relaxed state.

Insert pin
1 and carefully wrap the tube
counter-clockwise 90 degrees so it will just clear the insertion of pin
2 and 3.

Insert pins
2 & 3.

While holding the bent tubing down firmly into the fixture with one
hand, grasp the .012" wire that protrudes from the flared end of the
tube with a pair of pliers and pull the wire out of the tube. Pull in a
continuous (non-jerking) motion and pull the wire in a straight
direction. This will prevent distortion of the bent tubing.

Remove the formed tube from the fixture and cut and deburr the end to
the desired length.

Once the tubing is removed, inspect it for uniform shape. If slight
distortion occurred as a result of the support wire removal, it can be
gently reshaped using slight pressure with your fingers to straighten any
distortion.

Important note: The .012" wire can be lightly coated with thin oil prior to
inserting it into the tube. This will facilitate easier removal from the
formed tubing, HOWEVER... the remaining oily film inside the tubing will
make pushing the magnet wire through the bent tube very difficult. If oil is
used, squirt some type of cleaning solvent through the tube and thoroughly
dry it before proceeding.

In all cases, the way
we've found easiest and quickest to cut tubing to length is to simply snip it
slightly oversize in length (using ordinary side cutters) and then, using a
Dremel and sanding disk sand off the crimped ends until the tube is round and to
the length you need. The .018” tube inside diameter can easily be deburred using
a #80 drill bit in a pin vise. The external diameter is deburred using an
Arkansas stone or fine sand paper.